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MX28B200
User Manual
61 pgs922.89 Kb0

American Power Conversion MX28B200 User Manual

MX28B200/400
-48 VDC POWER SYSTEMS User’s Manual
(Document # 990-9133)
Table of Contents
1.1. WARNING SYMBOLS .........................................................................................................1
1.2. GENERAL PRECAUTIONS:.................................................................................................1
2.1. GENERAL I NFORMATION................................................................................................... 3
2.2. HOW TO USE THIS MANUAL.............................................................................................5
3.1. UNPACKING EQUIPMENT..................................................................................................7
3.2. MECHANICAL I NSTALLATION............................................................................................. 7
Room / Location.......................................................................................................................7
Mounting....................................................................................................................................7
Ventilation.................................................................................................................................8
3.3. AC POWER CONNECTIONS ..............................................................................................8
3.4. BATTERY CONNECTIONS ..................................................................................................9
Planning the Battery installation............................................................................................9
Connecting the Cables ............................................................................................................9
Battery Temperat ure Probe Installation.............................................................................10
3.5. DC SYSTEM GROUNDING.......................................................................................10
3.6. DC POWER OUTPUT OVER-CURRENT PROTECTION ....................................................11
DC Circuit Breakers...............................................................................................................11
DC GMT Fuses......................................................................................................................13
3.7. INSTALLATION OF CIRCUIT BREAKERS AND FUSES........................................................14
Plug-in Circuit Breaker Installation......................................................................................14
GMT Fuse Installation...........................................................................................................15
3.8. LOAD CONNECTIONS ......................................................................................................15
Cable Size Considerations...................................................................................................15
Circuit Breaker Connections (1 to 50 Amps).....................................................................15
Circuit Breaker Connections (60-100 Amps).....................................................................16
GMT Fuse Connections........................................................................................................17
3.9. MONITORING AND RELAY OUTPUT CONNECTIONS ........................................................18
Front Panel DB9 Connection...............................................................................................18
“Smart” Cable DB9 Connection...........................................................................................18
RJ45 Ethernet Connector.....................................................................................................18
Relay Output Connections...................................................................................................18
3.10. EXTERNAL ALARM I NPUT CONNECTIONS .......................................................................19
3.11. RECTIFIER MODULE I NSTALLATION................................................................................20
3.12. INITIAL POWER-UP AND CHECKOUT ...............................................................................20
3.13. SYSTEM PARAMETERS VERIFICATION/ADJUSTMENT.....................................................21
3.14. FULL SYSTEM POWER UP ..............................................................................................22
MX28B200/400 –48 VDC User’s Manual (990-9133) Page iii
4.1. TECHNICAL DESCRIPTION...............................................................................................23
4.2. RECTIFIER MANAGEMENT...............................................................................................23
AC Input Power......................................................................................................................23
DC Output Power...................................................................................................................23
Rectifier alarms reporting.....................................................................................................23
4.3. SYSTEM MANAGEMENT..................................................................................................24
System Output Capacity.......................................................................................................24
System Voltage Control........................................................................................................24
System Current......................................................................................................................24
System Status and Alarm Reporting ...................................................................................25
4.4. DC DISTRIBUTION ..........................................................................................................25
4.5. BATTERY MANAGEMENT .................................................................................................25
Battery Charging and Protection.........................................................................................25
Battery Temperature Compensation ...................................................................................26
Battery/Load Low Voltage Disconnect...............................................................................26
4.6. CONTROLS AND I NDICATORS..........................................................................................26
Front Panel User Interface...................................................................................................26
Parameter Locations, Descriptions, and Default Values.................................................28
Control Unit Menu Structure.................................................................................................37
Front Panel LED Indicators..................................................................................................42
4.7. ALARM OUTPUTS (OUTPUT RELAYS).............................................................................43
4.8. EXTERNAL ALARM I NPUTS (INPUT RELAYS)..................................................................43
5.1. DESCRIPTION..................................................................................................................45
5.2. PHYSICAL CONNECTIONS...............................................................................................45
5.3. COMMAND AND MONITORING PROTOCOL......................................................................45
6.1. AC I NPUT........................................................................................................................47
1MRF28H54BV Rectifiers....................................................................................................47
1MRF28H54BV50 Rectifiers................................................................................................47
6.2. DC OUTPUT (WITH EITHER 1MRF28H54BV RECTIFIERS AND 1MRF28H54BV50
RECTIFIERS).................................................................................................................................47
6.3. CONTROLS AND I NDICATORS..........................................................................................48
Rectifiers.................................................................................................................................48
6.4. CONTROLS AND I NDICATORS..........................................................................................49
Power Shelf Control Unit......................................................................................................49
6.5. MECHANICAL...................................................................................................................49
6.6. ENVIRONMENTAL............................................................................................................51
6.7. COMPLIANCE...................................................................................................................51
Page iv MX28B200/400 –48 VDC User’s Manual (990-9133)
Revision History
Revision Date By Description
1 31 JAN, 2002 JNF Converted to APC numbering 2 17 MAY, 2002 BET Updated Format
Table of Figures
MX28B200/400 –48 VDC User’s Manual (990-9133) Page v
1 Safety First!
It is very important to follow all safety procedures when unpacking, installing and operating any sort of power equipment.
1.1. Warning Symbols
CAUTION: An indication that special care is required to
prevent injury, equipment damage or misuse
WARNING: An indication of an electrical hazard that may
1.2. General Precautions:
cause serious personal injury or death, catastrophic equipment damage or site destruction..
WARNING: The DC power plant is supplied from a nominal 220VAC, 50/60 Hz source. Keep the AC input enclosure cover
in place when the system is operational or energized
WARNING: Hazardous energy levels are present on bare conductors in the -48VDC distribution connection area of the plant. Accidental shorting of distribution conductors can cause arcing and high currents that can cause serious burns or other physical harm. It is recommended that:
• Any jewelry, rings or watches be removed while working
WARNING: Ensure that all of the DC and external AC circuit breakers are in the OFF position prior to connecting service to
Specific CAUTION and WARNING will be placed in manual where appropriate .
the power plant. Confirm that all voltages have been removed including any battery sources before proceeding.
on this equipment.
• Handles of all wrenches, screwdrivers, cutters and pliers are insulated.
• Shafts of screwdrivers are wrapped in electrical tape or otherwise insulated
MX28B200/400 –48 VDC User’s Manual (990-9133) Page 1
2 Introduction
2.1. General Information
DC Power Plants from APC have unique features that make them easy to install, maintain, and upgrade. The rectifier units are modular and truly “hot -pluggable” into the shelf assembl y without any separate AC wiring. All system settings are made from the system control unit that provides monitoring and control functions for each component of the system as well as alarm listings for system diagnosis and maintenance.
The APC Model MX28B is a modular stand-alone -48V DC power plant. It is configurable in such a manner that it will support most typical applications within the specified current ranges (either 200 or 400 amperes) without special application engineering or assistance. Distribution is included for up to 24 plug-in circuit breakers. These circuit breakers can be 1 to 100 amps, with 60-100 amp breakers requiring two positions and a circuit breaker adapter kit. An optional low voltage disconnect (LVD) can be provided on either the battery or the load side. A 400 amp MX28B is shown in Figure 2.1-1 MX28B-400 –48 VDC Pow er Plant. A block diagram is shown in Figure 2.1–1.
Figure 2.1-1 MX28B-400 –48 VDC Pow er Plant
MX28B200/400 –48 VDC User’s Manual (990-9133) Page 3
Figure 2.1-2 MX28B BLOCK DIAGRAM
Page 4 MX28B200/400 –48 VDC User’s Manual (990-9133)
2.2. How to Use This Manual
Each section of this manual can be read in any order and should provide a complete explanation of the subject described by the title. However, the sequence of the sections is designed to provide a typical step-by-step process for successful use of the equipment.
Safety First! Safety symbol description and general precautions.
Introduction Brief system preview and explanation of manual
usage.
Installation How to unpack, install and commission the
equipment for initial use.
Operation Specifics of controls settings and indicators used to
operate the unit.
Remote
Monitoring
Specifications Power plant and rectifier specifications.
APC Worldwide
Customer Support
Warranty Equipment warranty terms and conditions.
Special remote monitoring and control features
described with references to information on auxiliary equipment.
How to contact APC for customer support.
MX28B200/400 –48 VDC User’s Manual (990-9133) Page 5
3 Installation
3.1. Unpacking Equipment
Remove equipment from packing material and inspect for shipping damage or missing items. It is important to report damage or material shortages to the shipping carrier while a representative is on site.
If concealed damage or material shortages are found at a later time, contact the shipper to make arrangements for inspection and claim filing. Refer to Section 7 in the event it is
necessary to return equipment to APC.
CAUTION: Appropriate lifting techniques and safety equipment should be used to remove equipment from packing.
PLEASE RECYCLE: The shipping materials can be recycled. Please save them for later use or dispose accordingly.
3.2. Mechanical Installation
Room / Location
NOTE: The APC Model MX28B DC power plant is to be installed in a room,
vault, or similar enclosure that is accessible only to qualified persons in accordance with the NEC or the authority having jurisdiction.
Prior to installation, drawings, floor loading requirements, external alarm points, AC service entrance, and grounding schemes should all be checked and confirmed. If batteries are to be mounted in a room separate from the power plant, careful attention should be paid to battery cable voltage drop effects. Environmental operating temperatures and ventilation/cooling considerations should also be noted, not just for the power system but also for all other equipment that may reside in the power room area.
Mounting
Both front mounting on standard 23-inch rails and optional wall mounting are available.
MX28B200/400 –48 VDC User’s Manual (990-9133) Page 7
Ventilation
The rectifier modules for this system have fans that provide front-to-rear airflow for internal cooling. The MX28B housing should mounted such that there is free airflow to the front, top, and bottom of the unit. [Refer to Section 6.6 for environmental characteristics.] Free airflow should be ensured so that the power system can provide full power at a given ambient temperature rating without de-rating.
3.3. AC Power Connections
WARNING: Ensure that all of the external DC and AC circuit
breakers are in the OFF position prior to connecting service to
The MX28B DC power plant requires the supply of 208/220/240/277 VAC single-phase, 50/60 Hz power through individual external 20-amp circuit breakers to the AC input terminal block connections for each rectifier module in the system. Two rectifier modules are required to accommodate the full AC input voltage range. The 1MRF28H54BV rectifier is designed for the standard 208/220/240 VAC input service, while the 1MRF28H54BV50 is used for the 277 VAC input. The AC wiring, from the AC input terminal block connections to the hot -pluggable AC input connector for each rectifier, is factory installed.
The AC input enclosure, located at the top right rear of the MX28B housing, is provided with two one-inch conduit entry holes and an access cover. Inside, a terminal strip(s) for AC input power connection and a separate “Earth Ground” bar for connection of the safety ground wire(s) are provided. The terminal block(s) is labeled as Position 1 through Position 4 (Position 1 through Position 8 for the 400-amp unit) with each posit ion having inputs designated “L1” and “L2/N” for connection of the two AC wires. Positions 1-4 correspond to the top rectifier shelf positions from left to right. Positions 5-8 are applicable to the 400-amp unit only and correspond to the lower rectifier shelf positions from left to right.
The suggested wire size is #10 AWG rated at 90°C or higher; however, the ambient temperature and number of wires in a conduit must also be considered in accordance with NEC requirements. It is suggested that feeds for four rectifiers (8 wires) and one safety ground wire be run in a one-inch conduit; however, be sure to follow any local electrical wiring codes.
If the AC input power is provided from a three-phase distribution panel, the circuit breaker positions should be selected such that the load is balanced as much as possible.
the power plant. Confirm that all voltages have been removed including any battery sources before proceeding.
Page 8 MX28B200/400 –48 VDC User’s Manual (990-9133)
WARNING: The MX28B DC power plant is supplied from a nominal 220VAC, 60 Hz source. Keep the AC input enclosure in place when the system is operational or energized.
3.4. Battery Connections
WARNING: Hazardous energy levels are present on bare
conductors in the -48VDC distribution connection area of the plant. Accidental shorting of distribution conductors can cause arcing and high currents that can cause serious burns or other physical harm. It is recommended that:
• Any jewelry, rings or watches be removed while working
Planning the Battery installation
The battery cable(s) should be sized sufficiently large to limit the voltage drop from the MX28B DC power plant to the battery during charging per system design requirements. The cable(s) must also carry the full load cu rrent during battery operation. If assistance is required to determine the necessary cables for the application, contact your sales representative or APC.
An external fuse or circuit breaker (various options are available from APC) is required in the negative line (located at the battery end) to protect the cables from the battery to the MX28B DC power plant. The power plant can monitor auxiliary contacts from this breaker.
Connecting the Cables
on this equipment.
• Handles of all wrenches, screwdrivers, cutters and pliers be insulated.
• Shafts of screwdrivers be wrapped in electrical tape or otherwise insulated
WARNING: Make certain that the battery polarity is correct when making connections to the Model MX28B DC power plant. Incorrect connection could cause severe equipment
The battery cable connections are located at the top rear of the unit as shown in Figure
3.4-1. The battery positive (return bus) and battery negative (-48V bus) buses each provide two sets of threaded 3/8”-16 holes on one-inch centers for connecting two-hole battery cable lugs. Connect the battery cables as applicable using 3/8-16 bolts (not provided) and tighten them with a torque wrench to 200 in -lbs (23 N-m).
MX28B200/400 –48 VDC User’s Manual (990-9133) Page 9
damage.
Figure 3.4-1 Battery Cable Connection Locations
Battery Temperature Probe Installation
The optional temperature probe is used to monitor the battery string temperature. To get the most representative temperature measurement, the probe should be placed in contact with a battery cell that is centrally located. The probe should be placed directly in contact with the cell (not the frame surrounding the cell). Generally, the cell cover can be used; be careful not to allow the probe body to touch the terminals. Plug the connector end of the temperature probe into J5 of the control unit backplane card. Route the cable as requir ed positioning the probe on the selected battery cell. Remove the adhesive protection strip from the probe body and press the adhesive side of the probe on the battery cell cover.
3.5. DC SYSTEM GROUNDING
The Positive Battery connection (return bus) for the power plant must be connected to the Master Station Ground. The left end of the return bus provides a pair of threaded 3/8-16 holes on 1 inch (25.4 m) centers for connection of a two-hole lugged cable to the Master Station Ground. Details for this connection should be provided in the site electrical grounding plans.
Page 10 MX28B200/400 –48 VDC User’s Manual (990-9133)
3.6. DC Power Output Over-Current Protection
DC Circuit Breakers
A standard 24-position plug-in circuit breaker tier provides -48V distribution. Various circuit breaker sizes from 1 to 100 amps are available, with 60-100 amp breakers requiring two positions and a circuit breaker adapter kit. The breaker tier is connected at its center to the -48V DC bus, and each side has an ampacity of 300A. It is therefore necessary to balance the load on the MX28B-400 plant to avoid overloading the output bus. Also when planning the output installation, take into consideration the configuration of the plant and the number of rectifiers installed. Any combination of up to 24 single (1-50 Amp) or up to 12 double (60-100 Amp) breakers may be installed. Figure 3.6-1 shows the power plant’s DC distribution section with the front cover removed.
Figure 3.6-1 DC Distribution (Front Cover Removed)
Available plug-in circuit breakers are shown below. These are only breakers and do not include any hardware.
MX28B200/400 –48 VDC User’s Manual (990-9133) Page 11
Plug-in Circuit Breakers
BREAKER
RATING
1 A FFA -0014 40 A FFA -0020 3 A FFA -0015 50 A FFA -0025
5 A FFA -0016 60 A 530-9088 10 A FFA -0017 70 A 530-9089 15 A 530-9093 80 A 530-9090 20 A FFA -0018 100 A 530-9091 30 A FFA -0019
PART NUMBER BREAKER
RATING
PART NUMBER
Plug-in circuit breakers rated at 60A or more require two mounting positions and require a circuit breaker adapter, which is included in the circuit breaker kit. Adaptors are available with studs for #10-32 nuts on 5/8” centers, #10-32 nuts on ¾” centers, or ¼-20 nuts on 1” centers. The circuit breaker kit includes all necessary mounting hardware. Available plug-in circuit breakers are shown below.
BREAKER
RATING
60 A FFA -0021-1 60 A FFA -0021-2
60 A FFA -0021-3 70 A FFA -0022-1 70 A FFA -0022-2 70 A FFA -0022-3 80 A FFA -0023-1 80 A FFA -0023-2 80 A FFA -0023-3
100 A FFA -0024-1 100 A FFA -0024-2
PART NUMBER ADAPTOR SIZE
Plug-in Circuit Breaker Kits
#10 studs on 5/8” centers
#10 studs on ¾” centers
¼” studs on 1” centers
#10 studs on 5/8” centers
#10 studs on ¾” centers
¼” studs on 1” centers
#10 studs on 5/8” centers
#10 studs on ¾” centers
¼” studs on 1” centers
#10 studs on 5/8” centers
#10 studs on ¾” centers
100 A FFA -0024-3
¼” studs on 1” centers
Page 12 MX28B200/400 –48 VDC User’s Manual (990-9133)
DC GMT Fuses
Eight GMT fused outputs are also available as an option. This option uses one of the 24 available circuit breaker positions. Connections to the GMT fuses are made at terminal block connectors labeled “F1” through “F8” that are located on the interface card mounted in the top left side of the unit. See Figure 2.1-1 for details. A list of GMT type fuses available from APC is provided below.
GMT Fuses
FUSE RATING PART NUMBER
¼ A FFA-0030 ½ A FFA-0031
3/4 A FFA-0032
1 A FFA-0033 1¼ A FFA-0039 1½ A FFA-0035
3 A FFA-0036
5 A FFA-0037 7½ A FFA-0029
10 A FFA-0038
Fuse cover 890-0052
MX28B200/400 –48 VDC User’s Manual (990-9133) Page 13
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